Method for remelting sprue material

ABSTRACT

A method for remelting plastic sprue material remaining adjacent a mold in an injection molding machine after an injection molding cycle of operation. Pressure is applied in a conventional manner to heated plastic for passage through a heated nozzle member in an injection molding machine. The nozzle contains a shuttle member which is moved to an injection position as the melting heated plastic is passes through the nozzle and the shuttle member, through a sprue line and then to the mold cavity. After the plastic solidifies in the mold cavity, a sprue removal pin is passed through the sprue line so as to remove the waste material or sprue material from the sprue line. This movement of the sprue removal pin moves the sprue back towards the nozzle and the sprue moves the shuttle member to a retraction position. The sprue then passes through a second path of travel which is past the heated portion of the nozzle for reheating and remelting the sprue material for later use thereof in an injection molding cycle.

July 16, 1974 SHER R 3,824,298

METHOD FQH REMELTING SPRUE MATERIAL Original Filed June 1, 1971 METHOD FOR REMELTING SPRUE MATERIAL K'eniieth E. Sher-er," Richmond, Ind., assignor to National 'Automatic'Tool Company, Inc. riginal application 'June 1, 1971, Ser. .No. 148,630.

" ;Divided "and this application Oct. 30, 1972, Set.

. 1: .Int. C1,.B29f1/05 .II.S.Cl.264 11 I 3 Claims ,7 ABSTRACT OF THE DISCLOSURE A method for remelting plastic sprue material remain- ..ing adjacent a-mold in an injection molding machine after "an injection molding cycle of operation. Pressure is ap pliedjin a conventional manner to heated plastic for pas- ,sage through, a heated nozzle member in an injection moldingmachiuel The'nozzle contains a shuttle member whichis moved to an injection position as the melted heated plastic passed through the nozzle and the shuttle member, through a sprue lineand then to the mold cavity. 4

1 REFERENCE TO'RELATED APPLICATION This application is a divisional of my co-pending appli- "c'a'tion forp'atenty entitled .Apparatus for Remelting Spru'e' Material,"Ser. No. 148,630, filed June 1, 1971, "'now U.S. Pat. No. 3,712,777.

.JEACKGROUND OF THE'INVENTIONFIELD OF ...T HE IN YENTION ANllDESCRIPTION OF THE :.;,RRIO RA.RT, =This inventionrelates to a method for remelting plastic s pruematerial which is formed following an injection {molding"operation .in an injection molding machine.

In injectionmolding operations, melted plastic is forced "under pressure intox'a mold. The plastic is solidified in the m'old and the molded part isremoved. It is conventional ininjectionimolding operations for the pressurized melted plastic t'o pass'runder Pressure from the injection nozzle h'rough a conduit ora sprue .line before the fluid plastic introduced into the mold. Since the pressurized plastic itself forces the plastic into the mold, plastic waste or sprue inaterialforms in the sprue line. In some operation's, th e'sprne solidifies on thepart itself and must be remov'edffrom the. part ina later operation before the part "is 'placed s into condition for use. ;Alternatively, at least' part of thef'sprue material may be removed from the inold-karea so that the sprue material will be sub- "stantia lly separatedtfrom the part which is being made.

'*In this alternative arrangement, at least in some molding,-

operations, itis considered desirable to use this at least partially solidified sprue material in a subsequent molding cycle. Since the sprue is at least partially solidified, it is necessary to. reheat and remelt the sprue material for lateri'usem I 1 *As a'specific example wherefreuse of sprue material i 'is considered 'rdesirable, 45 rpm. records are conventionallyumolded two at a time in-a sandwich type mold. -Molding of these 'records is automated to a high degree I and it is considered highly desirable for the plastic sprue material that is used for feeding the plastic to the mold SUMMARY OF THE INVENTION It is therefore an important object of this invention to provide an injection molding method wherein the sprue material is remelted following an injection molding operation so that the sprue material may be used as material to be injected into the mold cavities.

It is also an object of this invention to provide a method for injecting plastic material into mold cavities and thereafter removing material from the sprue line for remelting in a heated nozzle so that the remelted sprue material may be used in a subsequent injection molding operation.

It is further object of this invention to provide an injection molding method which provides a nozzle member having a shuttle member contained therein, the shuttle member defining a first path of travel in a first position for pressurized melted plastic during injection of plastic into the mold cavities and defining a second path of travel in a second position for passing the sprue material adjacent the heated nozzle for remelting of the sprue material for subsequent use.

It is further object of this invention to provide an improved method for conveniently, simply, and economically, reheating and remelting sprue material during an injection molding cycle of operations whereby the sprue material may be used in a later injection cycle.

It is yet another object of this invention to provide an injection molding method which provides a sprue removal device which is in cooperative relationship with a shuttle member contained within a heated nozzle member for forcing the sprue material to a position adjacent the heated zone of the nozzle so that the sprue material may be reheated and melted for use.

Further purposes and objects of this invention will appear as the specification proceeds.

The foregoing objects are accomplished by my method for remelting sprue material wherein the steps include applying pressure to melted plastic in an injection molding machine, passing the melted plastic in one direction through a nozzle in a first path of travel, introducing the pressurized and melted plastic into a mold, solidifying the plastic in the mold, a portion of said plastic remaining outside of the mold and forming the sprue material, driving the sprue material in a reverse direction from the one direction, passing the sprue material through the nozzle in a second path of travel, and reheating and remelting the sprue material during passage through the second path of travel.

BRIEF DESCRIPTION OF THE DRAWINGS A particular embodiment of apparatus useful in the practice of the present invention is illustrated in the accompanying drawings; wherein:

FIG. 1 is a schematic, longitudinal cross-sectional view through an injection molding machine useful in my sprue remelting method, the apparatus being shown during the injection phase of operation; and

FIG. 2 is a schematic view, like FIG. 1, except the apparatus is shown during the retraction phase of operations EMBODIMENT Theaccompanying drawings illustrate, generally in schematic form a portion of an injection molding machine,

generally 10. The injection molding machine 10, includes an end cap 12 having a nozzle member 14 mounted thereon. The outer end or tip 16 of the nozzle 14 is movable into sealing engagement with a sprue bushing 18 for the injection of pressurized plastic therein. The sprue bushing 18 is mounted on a die head 22 which also has a locating ring 24 mounted thereon.

The end cap 12 carries an injection screw 26 which rotates and reciprocates. The injection screw 26 includes a tapered outer end or tip 28, which is movable between the retraction or starting position, shown in FIG. 2, and the injection position, shown in FIG. 1. The screw tip 28 is located within the cavity 30 of the end cap 12, the screw tip 28 being tapered at substantially the same conical shape as the interior surface of the cavity 30 in the end cap 12. The cavity 30 terminates with a cylindrical outlet 32 through which pressurized and melted plastic is passed during the plastic injection operation.

The nozzle member 14 is hollow and is sealably mounted by thereaded interconnection 34, to the outer end of the cap 12. The nozzle member 14 projects outwardly from the end cap 12 and includes an outer end or tip 16 with a hollow central portion 36 which directly aligns with the outlet 32 of the end cap 12. The hollow central portion 36 is substantially coaxial with the outlet 32 and with a discharge opening 38 defined in the outer tip 16 of the nozzle 14.

During injection molding the pressurized plastic passes outwardly through the discharge opening 38 after the nozzle tip 16 is moved into sealing engagement with the sprue bushing 18, as previously described. The sprue bushing 18 includes a sprue line or conduit 40 which is substantially straight and coaxial with the nozzle 14. The sprue line 40 leads to one or more cavities 42 in which the plastic molded parts are formed. In the specific embodiment shown, sandwich type mold cavities for forming 45 r.p.rn. records are illustrated. It is to be understood, however, than any suitable type of mold cavities may be used in conjunction with this invention.

Referring to FIG. 1, in the injection position, after the mold cavities are filled with plastic and solidified, therein, plastic material also solidifies in the sprue line 40. Although this material is often considered waste material, this sprue material, in my invention, is remelted and used in a later injection cycle.

In order to accomplish remelting of the sprue material, a heating band or element 44 is positioned around the reduced forward portion 46 of the nozzle member 14. Suitable electrical leads 48 are connected to an electrical wire for heating band 44 to the desired temperature level. The heating band '44 thereby raises the temperature of walls 50 defining the forward portion 46 to a desired temperature for remelting the sprue material for use in a subsequent injection molding cycle of operation.

In order to accomplish the desired injection of plastic into the mold cavities 20 during the injection phase of the operation, and to accomplish remelting and reheating of the sprue material during the retraction phase, it is important to provide a shuttle member 52 within the hollow central portion 36 of the nozzle member 14. The shuttle member 52 is a substantially hollow member which is coaxially mounted with the hollow central portion of the nozzle 14, which in turn is co-axial with the discharge opening '38 and with the outlet 32 on the end cap12. The inner end of the shuttle member 52 has a relatively large opening and is movable into direct communication with the outlet 32 in the end cap 12. The opposite end of the shuttle member 52 includes an orifice 54 of reduced diameter. More specifically, the orifice 54 is of such a size as to permit passage of melted plastic material therethrough in the injection phase of operation but to prevent passage of the sprue material therethrough in an opposite direction. It has been found that an orifice size of about .060 inches provides advantageous results.

At the rearward portion 56 of the shuttle member 52, a

plurality of uniformally'spaced apertures58 are provided.

Theouter configuration of the shuttlegnemberj} is sig; nificantly less than the interior diameter of the hollow portion 36 of the nozzle member 14 so as to define a sub stantially annular channel 60 therebetween. In order to provide this annular spacing, a suitable number of spacing ribs (not shown) are provided either on the-outer surface of the shuttle member 52 or on the'innersurface of the wall Stlof the hollow central. portioni36 of the nozzle member 14. The apertures 58 providefor intercommunication between the annular chamber 60and the hollow interior 62 of .the shuttle member"'52-. Theshuttle member 52 is reciprocally movable between the injection position shown in FIG. 1 and the retraction position shown in FIG. 2, which operation will be described hereinafter in greater detail.

In order to remove the sprue material frornthe sprue line 40, a reciprocal sprue removal pin 64 is provided .'The pin is movable between a first position, downstrearn'of the outermost cavity 42 and a position whiche'xt'ends through the discharge opening 38 of the nozzle member 14, following removal of substantially all ofthe sprue material from the sprue line '40 and frorn th'e discharge opening 38 in the nozzle 14. J I

My improved method for reheating, remelting and r eusing the sprue material will beunderstood by a description of operation of the apparatus described above. I

Referring to FIG. 2, the screw tip 28 is shown in its retracted position and a measured amount of melted plastic is stored in front of the screw tip following screw rotation. At this time, the screw tip 28 is spaced from the tapered cavity 30 and the end cap 12. When the molds are closed by suitable means (not shown), the injection screw 26 moves forward inside the end cap 12 and forcesthe melted plastic under pressure, through the end capou tljet 32 and into the nozzle member 14.

The pressure of the melted plastic acting against the shuttle member 52 drives the shuttle member 52 from the retracted position shown in FIG. 2 to the injection'position shown in FIG. 1. The outer end of the shuttle'mernber 52 defines an annular sealing engagement together with the inner spherical section at the outer end of .the hollow central portion 36 of the nozzle 14 so as to pre vent passage of the melted plastic material from: the. annular chamber 60, between the shuttle member 52 and the nozzle member walls 50, directly to the nozzle discharge opening 38. With this sealing arrangement, the prescavities 42, solidified sprue material is formed inithe sprue line 40. a

At this time, the sprue removal pin 64 is moved directly against the sprue material in the sprue line 40:::This.returns the pliable solidified sprue material towardsand. into the nozzle member 14. When thesprue; material contacts the outer end of the shutle member 52, the shutle-rnemb'er 52 is forcibly moved away from sealing engagement with the hollow interior of the nozzle member 14. Theshuttle member 52 is moved in thismanner until the annular inner end of the shuttle member 52 strikes or engagestheouter end of the end cap 12, which therebyacts as astro ke limiting member. 1

As the sprue is pushed against the shuttle member .52, the plastic sprue moves around the shuttle member;52,:a,s5'it cannot pass through the orifice 54,'and into the annular chamber 60. In the chamber '60, the sprue material isnin "intimate contact with the heated Walls 50 ofth'elnozzle member 14. This results in rapid melting of the sprueiniaterial which is then passed into the hollow shuttlet52 through the uniformally spaced apertures at the rear portion 56 of the shuttle 52. Sprue removal may be facilitated by retraction of the screw tip 28 at a controlled rate before the sprue removal pin 64 is forced against the sprue material, whereby the pressure inside the hollow shuttle member is substantially reduced. The sprue removal pin 64 is used until substantially all the sprue material has been melted.

When the sprue removal pin is in the position shown in FIG. 2, the screw 26 may be rotated to assure adequate melting of the thermoplastic material for the next shot or injection molding operation. When a measured volume of plastic material is again prepared, the rotation of the screw has been stopped, the sprue removal pin 64 is retracted from the position of FIG. 2 to that of FIG I. The mold halves (not shown) are then opened and the mold parts are removed from the mold cavities 30.

While in the foregoing there has been provided a detailed description of a particular embodiment of the present invention, it is to be understood that all equivalents obvious to those having skill in the art are to be included within the scope of the invention as claimed.

What I claim and desire to secure by Letters Patent is:

1. A method for remelting sprue material remaining after an injection molding operation, said method comprising the steps of applying pressure to melted plastic, passing said melted plastic in one direction through movable nozzle containing a orificed shuttle means in a first path of travel, introducing said pressurized melted plastic into a mold, solidifying said plastic in said mold, a portion of said pressurized melted plastic outside of said mold and thereby forming said sprue material, driving said sprue material in a reverse direction opposed to said one direction of said melted plastic, while the orifice blocks return of sprue material moving said orificed shuttle means for defining a second path of travel, passing said sprue material through said second path of travel, and reheating and re melting said sprue material during passage through said second path of travel.

2. The method of Claim 1 wherein the passage of said sprue material through said second path of travel is in a direction opposite the movement of said melted plastic in said first path of travel.

3. The method of Claim 1 including the step of moving said orificed shuttle means for defining said first path of travel in response to the step of passing said plastic in one direction through said nozzle means.

References Cited UNITED STATES PATENTS 2,613,395 10/1952 Massler 264-329 X R 2,698,460 1/1955 Amo 264-329 X R 2,698,464 1/1955 Wilson 264329 X R RICHARD R. KUCIA, Primary Examiner.

US. Cl. X.R. 

